Vestermark, Oskar

Abstract [en]

In today’s society the car is used more and more and the new car sales steadily increase. To be able to continue this development the automotive industries invest a lot of money and effort on developing their cars. Because it’s the most environment friendly, safest or perhaps the fastest car that sells. The common factor for all this properties is that the car body performances need to be enhanced. Then Accra enters the picture with their knowledge in roll forming and hardening of boron steel they can create profiles that enhance the cars performance. To do this in an optimized way it’s of importance to join the profiles in a way that is enabling the individual profiles performance to bond together and create a structure with the intended features. Therefore, there is a great need for an optimized way of joining these roll formed boron profiles to meet the auto motive industries demand on improved performance. During the work with this thesis I have developed a concept for joining two roll formed profiles. The work was concentrated on a specific node in the car body. To be able to use the available information to create an effective node. Then the result would be possible to use when designing different nodes in a car body structure. The result is a 3D modelled prototype that has been developed with the help of finite element methods. The node meets the demands and the requirements with success. To validate the simulations and to test a simplified node, prototypes has been manufactured and tested. The result of the test confirms the simulations and the design of the node. With this node the weight of the system could be decreased with 5 kg only by replacing two nodes and three stamped profiles in the car body. It also reduced the system with 8 details. Proceeding with this concept and use it in other nodes in the car body it will be possible to save considerably weight. This should also lead to the creation of safer and more environmental friendly cars.